Method and plate apparatus for dew point evaporative cooler using a trough wetting system

ABSTRACT

An improved method and apparatus for indirect evaporative cooling of a fluid stream to substantially its dew point temperature. Plate heat exchanger has perforations ( 11 ) and channels ( 3, 4  and  5 ) for gas on a dry side and wet side. There is a trough formed in a portion of the plate that temporarily holds evaporative fluid which is in contact with the wick material on the wet side surface of the plate. The evaporative fluid flows through the trough by way of liquid perforations into the next trough. The trough of a plate with a wet side up, the liquid perforations are on the side creating a reservoir to wet the opposing wick materials. As streams flow across the dry side ( 9 ), transferring heat to the plate. Working gas stream ( 2 ) flows across the dry side and through perforations to channels ( 5 ) on wet side ( 10 ), which it then cools by evaporative cooling as well as conductive and radiative transfer of heat from plate.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 09/966,928, filed Sep. 27, 2001, entitled “METHOD AND PLATEAPPARATUS FOR DEW POINT EVAPORATIVE COOLER”, which claims the benefit ofU.S. Provisional Patent Application Serial No. 60/236,047, filed Sep.27, 2000, entitled “IMPROVED METHOD AND MEMBRANE APPARATUS FOR DEW POINTEVAPORATIVE COOLER”. This application Ser. No. 60/341,206, filed Dec.12, 2001, entitled “TROUGH WETTING SYSTEM DESIGN”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the field of evaporative fluid conditioning.More specifically, the invention relates to the field of sensiblecooling of fluids (gas, liquid or mixtures with and without phasechanges) to substantially the dew point for gas by indirect evaporativecooling within a heat exchanger having canalized gas and fluid flows anda lateral temperature gradient across the heat exchange plates. Furtherthe invention herein is directed to an improved membrane design, to aidin quick distribution of liquid, efficient reservoir system and acontrol system.

2. Discussion of the Background

Indirect evaporative cooling is a method of cooling a gas stream,usually air, by evaporating a cooling liquid, usually water, into asecond air stream while transferring heat from the first air stream tothe second. The method has certain inherent advantages compared toconventional air conditioning: low electricity requirements, relativelyhigh reliability, and the ability to do away with the need forrefrigerants such as R-134 and all the disadvantages they entail.However, indirect evaporative cooling is as yet only used in speciallybuilt commercial applications, and is not yet available on the market asa residential or after market product. This is due to certaindisadvantages of known indirect evaporative coolers and methods:excessive cost, ineffective thermodynamic cycle that does not allow forenough cooling of air for the expenses involved, ineffective watersupply system, scale buildup, poor or expensive heat exchanger,excessive pressure drop, difficulty approaching the dew point of the airstream (the theoretical limit of cooling), relatively high dew points inhumid atmospheres, large pressure drops across the heat exchangeapparatus, large heat exchange apparatus, and in some designs, relianceon a good deal of ancillary equipment.

U.S. Pat. No. 4,002,040 issued to Munters et al on Jan. 11, 1977discloses a heat exchanger in which there is no mixing between canalizedair streams, and in which the air stream passing through the device isput through a 270 degree turn within the device, resulting in a largepressure drop engendered by the flow path. Additionally, Munters doesnot allow for cooling fluids other than outside air and cannot be usedin applications where recirculation is desired.

U.S. Pat. No. 5,187,946 issued to Rotenberg et al on Feb. 23, 1993, butcopies Maisotsenko Russian patent (2096257) discloses a heat exchangerhaving perforations through the heat exchange plates and alternating wetand dry channels. The present invention is different in substantial waysfrom the U.S. Pat. No. 5,187,964 disclosure (Maisotsenko Russian Patent2046257) does not use: a separate treatment of product fluids (cooledfluids, whether gas, as U.S. Pat. No. 5,187,946's disclosure is limitedto, or other fluids), the thin plastic plates that operate as efficientheat transfer from dry channels to wet channels yet do not transfer heatlaterally along the surface or the plates, or a shallow slope to theheat exchange plates to allow efficient wicking action, but insteaddiscloses a relatively high angle. It also does not reveal use of afeeder wick, or wick, or reservoir system instead using complex andcostly spray heads located in each wet channel. Finally, U.S. Pat. No.5,187,964 argues against the use of channel guides, urging thatturbulent flow provides better efficiency. However, this does not allowU.S. Pat. No. 5,187,964 to control the lateral temperature profile ofthe individual heat exchange plates. In addition in the currentinvention by separating the working air stream from the product theworking air decreases in flow as it passes through the channelperforations, reducing its pressure drop and at the same time allowingbetter control of the exhaust channels. U.S. Pat. No. 5,187,964, similarto Munters above is limited to cooling outside air.

U.S. Pat. No. 5,170,633 issued to Kaplan on Dec. 15, 1992, shows theamount of ancillary equipment which can proliferate in indirectevaporative systems. U.S. Pat. Nos., 5,727,394, 5,758,508, 5,860,284,5,890,372, 6,003,327, 6,018,953, 6,050,100, issued to Belding et al andGoland et al, display the same syndrome of excessive air treatmentequipment. In examining systems such as those referred to, it should beborne in mind that a single additional heat exchanger adds more than onethird to the overall cost of the system. These systems, aside from thedifferent methods again only apply for cooling air.

U.S. Pat. No. 5,453,223, dated Sep. 26, 1995, and nominally issued tothe present applicant, discloses an apparatus in which alternating setsof wet and dry plates provide two streams of air: one dry, cooled bycontact with the plates beside it, and one wet, cooled by directevaporation. However, the unit requires two gas flows in and two gasflows out. In addition, the design in question does not provide forindirect cooling only, without additional direct evaporative cooling.While such a second stage of direct evaporative cooling, raising thehumidity of the product air, is often desirable, it is as often notdesirable.

Two pending applications by the present inventor also address thetechnology of indirect evaporative cooling. PCT ApplicationPCT/US01/04082, filed Feb. 7, 2001, discloses one method of eliminatinga second stage of direct evaporative cooling. PCT ApplicationPCT/US01/04081 filed on Feb. 7, 2001, discloses better methods of designof the heat exchange cores of indirect evaporative coolers, allowingbetter wetting and reduced pressure drops.

An indirect evaporative method and apparatus providing more efficientair flow and heat transfer is desirable. The advantages of the improvedmembrane, reservoir and control mechanism of the indirect evaporativemethod and apparatus grant advantages over the previously discloseddesigns yielding more positive results.

SUMMARY OF THE INVENTION

The present invention provides an indirect evaporative cooler of fluidsof all types having cross flowing wet and dry channels on opposite sidesof a heat exchange plate which allows heat transfer through the platedue to thin plastic construction or other suitable materials butprevents or minimizes heat transfer laterally along the plate. Forpurposes of application, we wish to define certain terms:

1. Heat transfer surface or heat exchange surface has manyconfigurations. All are encompassed within the subject of this disclosedinvention with appropriate adjustment to the wetting and flows as arewell known in the industry. For the example of the illustration we makeuse of a plate configuration.

2. Wet side or portion of the heat exchange surface means that portionhaving evaporative liquid on or in its surface, thus enablingevaporative cooling of the surface and the absorption of latent heatfrom the surface.

3. Dry side or portion of the heat exchanger means that portion of theheat exchanger surface where there is no evaporation into the adjacentgas or fluid. Thus, there is no transfer of vapor and latent heat intoadjacent gases. In fact, the surface may be wet but not with evaporativefluid or wet by condensation, but no evaporation exists.

4. Working stream or working gas stream is the gas flow that flows alongthe heat exchange surface on the dry side, passes through the passagesin the surface to the wet side and picks up vapor and by evaporationtakes latent heat from the heat exchange surface and transports it outinto the exhaust. In some embodiments, the working stream may bedisposed of as waste and in others it may be used for special purposes,such as adding humidity or scavenging heat.

5. Product stream or product fluid stream is the fluid (gas, liquid ormixture) flow that passes along the heat exchange surface on the dryside and is cooled by the absorption of heat by the working gas streamon the wet side absorbing latent heat by the evaporation in the wetarea.

6. Trough wetting system embodiment is a feature of the membrane that onthe illustrations occurs in all membranes in a central area of themembranes and the troughs of adjacent membranes work in conjunction asliquid passage ways and as holding locations or reservoirs for purposesof wetting the wet side of the membranes. The location and shape, andrelative placement of this trough or trough like features are merelydepictions. Other orientation and methods and apparatus are encompassedwithin the disclosed invention.

The plate also has passageways or perforations or transfer means betweenthe dry side of the plate and the wet side in defined areas providingflow from the dry working channels to the working wet channels in whichdirect evaporative cooling takes place. By means of the perforations theworking gas streams have a pressure drop through the system, which isreduced.

The method of the invention makes use of the separation of a working gasflow (that is used to evaporate liquid in the wet channels and thus tocool the wet surface of the heat exchanger plate) from the product fluidflow, both flowing through dry product channels and dry working channelson the same side of the heat exchange plate and that both give up heatto the heat exchange plate that on its obverse surface is being cooledby evaporation in the working wet channels.

The working gas flow first enters the dry working channel and thenthrough perforations, pores or other suitable means of transfer acrossthe barrier of the plate to the wet side and thence into the wet workingchannels where evaporation of liquid on the wet channel surface, coolsthis plate.

The dry product channels are on the dry side of this plate. The plate isof a thin material to allow easy heat transfer across this pate and thusto readily allow heat to transfer from the dry product channel to thewet working channel. This is one basic unit or element of the inventionillustrating the method of the separation of working gas flows toindirectly cool the separate product fluid by evaporative cooling.

It is therefore on object of the invention to provide an indirectevaporative cooler having perforations allowing flow from dry workingchannels to wet working channels on the opposite side of the heatexchange plate.

It is another object of the invention to provide an indirect evaporativecooler having heat exchange plates, which do not allow substantiallateral heat transfer but do allow heat exchange through and across theplate. This produces a temperature transfer across the plate that is notaveraged out by lateral heat transfer down the plate. Averaging thetemperature down the plate would effectively reduce the temperaturedifference through and across the plate and results in lower heattransfer rates across the plate. Thus, it is part of this invention tohave heat readily transfer across the plate from the dry side to the wetside but not readily transfer along the surface of the plate.

It is another object of the invention to provide an indirect evaporativecooler having a temperature gradient across the two dimensional surfaceof the plate, and thus providing working gas stream channels having arange of temperatures.

It is another object of the invention to provide an indirect evaporativecooler allowing selection of the product fluid streams for use incooling, in particular, the fluid streams exiting from the coldestproduct channels may be selected for use in cooling. Conversely, theselection may be of some portion of the working gas streams to giveadded humidity to the environment.

It is another object of the invention to provide an indirect evaporativecooler having efficient wicking action allowing easy wetting ofsubstantially all of the surface area of the wet channels with outexcess water that cools the water rather then the air.

It is another object of the invention to provide an indirect evaporativecooler having a system providing liquid uniformly to all wet channels ofthe device. The system has features to quickly distribute the liquid toall wet membranes, to provide reservoirs for wetting and a controlsystem to adjust and control the liquid distribution.

It is yet another object of the invention to provide an indirectevaporative cooler having cycle selection means, so that during summermonths, it may be used to provide cooled, non-humidified air, and duringwinter months, it may be used to scavenge heat from gases exiting aspace while simultaneously humidifying the space.

It is yet another object of the invention to provide an efficientindirect evaporative cooler, allowing cooling of a stream of a productto substantially the working gas dew point temperature.

It is another object of the invention to provide an efficient indirectevaporative cooler having a relatively small pressure drop for workinggas streams.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) is a three dimensional perspective and schematicrepresentation of a first embodiment of the invention method, showingthe gas flow path of the working gas for cooling of the gas in passingthrough a perforation or passage from a dry side of a plate to a wetside of the plate. The dry side of the plate has separators to keep theworking gas path separate from the product fluid path.

FIG. 1(b) is a perspective and schematic representation of the obverseside of FIG. 1(a) showing the wet side with channels and depicting theworking gas flow after it goes through the passages and then along thewet surface of the channels where evaporation occurs.

FIG. 1(c) is a perspective and schematic representation of two plates,such as in FIGS. 1(a) and 1(b) showing the wet side channels formed bythe wet sides of a first and a second plate opposing each other, withtheir passages oriented in the same general area and illustrating theworking gas entering on the dry side, passing through the passages andinto the wet side channels. The product fluid is separated from theworking gas as they pass along the dry side of the first and secondplates. Additional plates would have adjacent plates having their dryside oppose the dry sides of these first and second plates. Thus, thestack of plates would have every odd plate oriented with its dry sidefacing the same direction and opposite of all even plates.

FIG. 1(d) is a three dimensional perspective and schematicrepresentation of a second embodiment of this aspect of the invention,showing a working gas flow path from the segregated working dry pathentering the wet side by perforations or passages and exiting one sideof the plate after passing across the wet surface of the wet surface ofthe wet working channel.

FIG. 2 is a three dimensional perspective and schematic representationof a third embodiment of this aspect of the invention, showing the gasflow path when the invention is used to warm and humidify an air stream.

FIG. 3 is a partially three dimensional perspective and schematicrepresentation of the flow path of a fourth embodiment of this aspect ofthe invention showing the working gas flow when the invention is usedfor cooling of a dehumidified product fluid, and further showing theproduct fluid flow in the context of use.

FIG. 4 is a partially three dimensional perspective and schematicrepresentation of the flow path of a fifth embodiment of this aspect ofthe invention showing working and product gas flow when the invention isused with recirculating gas flow, and further showing the gas flow inthe context of use.

FIG. 5 is a three dimensional perspective and schematic representationof an expanded assembly of multiple channels, showing dry side flow,additional perforations, and additional channel guides with theperforations predominately in the middle of the membrane. The dryworking gas enters and passes through the passages to the wet side (notshown).

FIG. 6 is a three dimensional perspective and schematic representationof the same expanded assembly of FIG. 5, showing wet side gas flow afterthe dry working gas passed through the passages. The surface of theplate has wicking material to carry liquid from the feeder wick methodto the edges of the plate and to supply the liquid for evaporationcooling.

FIG. 7 is a cross-sectional view of the assembly of FIG. 5 withadditional plates, showing gas flow with the side wings being angledupward from the mid point. The plate on top has its dry surface. Thebottom of this plate is wet and the channel guides orthogonal to the dryside channels. The second plate has its wet surface facing the firstplate's wet surfaces making the channels between the first and thesecond plate wet. The second plate has its dry surface on the bottom.Successive plates continue to match dry to dry surface, and wet and towet surfaces.

FIG. 8 is a perspective view of a two sided core with a feeder wickplate between the two sides and the upward angled wings orientation ofthe core layers from the center.

FIG. 9 is a partially exploded perspective view of an assembly of theinvention, including schematic representations of gas flow and fluidflow with upward angled wings of a core.

FIG. 10 is a partially exploded perspective view of an embodiment of theinvention using a plate such as FIG. 1(d) with the liquid supplied tothe wick material on the plates by a reservoir. There would besuccessive plates with dry dry and wet wet surfaces.

FIG. 11 is a perspective view of a two part core with a center feederwick plate between the two wings with the wings angled downward from thecenter and perforations in area of each layer nearest the center wick.

FIG. 12 is an embodiment of the feeder wick plate used in FIG. 8 withgrooves that run some or all of the way from the highest to the lowestpoint to speed liquid transfer to the bottom of the wick and to allowexcess liquid to be drained.

FIG. 13 is a second embodiment of the feeder wick plate with holethrough the inner part of the feeder wick plate.

FIG. 14 is a third embodiment of a feeder wick plate comprised of asandwich to aid quick distribution of liquid to the outer perimeters ofthe feeder wick plate and to aid drainage. The sandwich is comprised ofmaterials with two different porosities the middle layer having greaterporosity than the outer layer.

FIG. 15 is a perspective view of two cores similar to FIG. 8 with theair pathways shown and illustrating a separation gap between the twocores to aid in heat transfer rates by breaking up the paths intosegments and thus break up large pathways which create boundary layerswhich in turn inhibit heat transfer.

FIG. 16 is an assembly of a reservoir piping and valving in conjunctionwith a feeder wick plate usable in assembly such as FIGS. 8, 15 andother embodiments. The upper reservoir feeds the feeder wick plate. Thelower reservoir by way of a float valve determines if the wick is shortof liquid and thus having a lower reservoir level in the bottomreservoir, which then turns on the feeder valve to supply more liquid tothe top reservoir.

FIG. 17 shows the reservoir system of FIG. 16 incorporated with the coreassembly of FIG. 8.

FIG. 18 is a perspective view of another embodiment of a Type 1 plate,wet side up, showing working channels, and gas perforations with atrough formed in the plate having liquid perforations for liquid to passthrough to the next layer after it reaches a predetermined level in thetrough (on the bottom of FIG. 18), and a second trough plate Type 2similar to the Type 1 plate, but with the dry side up, with product andworking channels and the liquid perforations with trough location at thebottom of the trough (on the top of FIG. 18).

FIG. 19 is a perspective and schematic view of a stack of plates with aType 1 plate, and a Type 2 plate, and a second Type 1 plate and a secondType 2 plate and a third Type 1 and a third Type 2 showing the path ofliquid as it enters the top of the trough of the Type 2 plate from theplate above and exits the liquid perforations and drops to the trough ofthe next lower plate, a Type 1 plate where the liquid accumulates in areservoir until the liquid reaches the level of the liquid perforationin the sides of the trough where it exits and goes to the trough of thenext lower Type 2 plate and continues. The liquid thus cascades downwardleaving a reservoir of liquid in the trough of each Type 1 plate.

FIG. 20 is a perspective and schematic view of a stack of Type 1 andType 2 plates with a liquid feeder tube to supply liquid to the toptrough of this stack, and having a top plate and a working air seal tocontrol the air and liquid passage to the correct pathway.

FIG. 21 is a perspective and schematic view of a stack of Type land Type2 plates, as in FIG. 20, with liquid supply tubes at more than one leveland a bottom reservoir to collect liquid with a monitoring device todetect whether liquid needs to be added to the stack because of usagerates.

DETAILED DESCRIPTION OF THE INVENTION

Figure is a three dimensional perspective and schematic representationof an embodiment of a primary element of the invention demonstrating themethod by which indirect cooling occurs. This element embodiment isformed as a flat plate (and thus also referred to herein as plate 6),includes perforations 11 which connect dry side 9 to wet side 10. Dryside 9 is further subdivided and segregated into product channels 3 andworking gas channel 4: perforations 11 are within working gas channel 4.Wet side 10, see FIG. 1b, is wetted with an evaporative liquid toprovide cooling. Wet side 10 also has channel 5. Channels 3 and 4, FIG.1a, are segregated so the working dry gas is kept separate from the dryproduct fluid. Channel guides 8 define channels 3 and 4 by preventingintermixing of the gas between the channels 3 and 4 and relativelyfreely transfer across plate 6 from the perpendicular gas streams on theother side. As the plate 6 is very thin, heat may readily passperpendicular through and across this plate from the dry side to the wetside. The plate material is selected to minimize heat transfer along theplate. A preferred material is plastic. The materials of the channelguides aside from providing barriers to define channels may alsoadvantageously insulate the streams as much as possible from theadjacent parallel streams on both sides, thus offering a low rate of“parallel heat transfer”.

In use, a product stream of fluid 1 and a working stream of gas 2 arerespectively drawn into channels 3 and 4, traversing the dry side ofplate 6 in a laminar flow. Working gas stream 2 then flows throughperforations 11 to the wet side 10 and into channels 5. Channels 5 onthe wet side directs gas stream 2 in a direction somewhat perpendicularto perpendicular to the fluids flowing on the dry side and across thewet side 10 of plate 6, where it receives heat in several ways: first,in the form of evaporation of liquid from wet side 10 and second, asheat rejected by conduction and radiation from plate 6. Thus plate 6acts as a heat exchanger and as an indirect evaporative cooler. Gas flow2 emerges from the indirect evaporative cooler 6 as gas streams 2, asindicated in FIG. 1(a) and FIG. 1(b).

The cross flow need not be exactly perpendicular, as long as the flow is“substantially somewhat perpendicular”. At 180 degrees, the flow becomesa counter flow, and at 0 degrees, the streams on both sides of plate 6may be parallel. A substantially somewhat perpendicular flow may occurat an angle between these two extremes, provided the angle allows thestreams on opposite sides of the plate to cross each other. Theimportance of having the streams on opposite sides of plate 6 is thatthis provides a temperature gradient and temperature differentialdiscussed later.

In this embodiment all of working gas stream 2 passes over the center ofthe plate 6 in channel 4. On the obverse side of plate 6, under channel4, gas stream 2 is in contact with the wet side and is cooled byevaporation. At the inlet, stream 2 (on the dry side in channel 4) isbeing cooled by the evaporation on the obverse side of plate 6. Thisacts as precooling of stream 2. Thus as stream 2 proceeds down channel 4on the dry side before entering perforations 11, it's dry cooled toideally the wet bulb temperature. This precooling in the dry side,allows this stream to enter the wet side cooler than its originaltemperature therefore with a continuing lower wet bulb temperature.

The canalization of the gas streams 1 and 2 further increases theefficiency of the device by allowing control of the flow within it andcontrol of temperature. The temperature differential through and acrossthe plate 6 is generated by the flow of gas stream 2 through the wetchannels 5; at the start of the flow of gas stream 2 through the wetchannels 5, it is very dry and can absorb the maximum of vapor from theevaporative fluid. This in turn absorbs the maximum amount of latentheat (transition from liquid to vapor), which in turn allows for thegreater temperature differential through the plate 6. Thus channel 3nearest the channel 4 will be cooled the most.

In practice the product fluid may be any fluid (air, gas, liquid ormixed) for which dry cooling is desired, that is, cooling withoutaddition of a partial pressure gas component derived from evaporation ofthe cooling liquid. For example, in commercial and residential usage,the fluid may be air and the cooling liquid water: the product airstreams that emerge from the dry side channels invention do so withouthaving any humidity added. It can be refrigerants, either during phasechanges or not, to allow for cooling to lower temperatures before useand thus achieve greater efficiencies in the refrigerant cycle at lowcost.

In the embodiment pictured, in FIG. 1(a), the segregation of the workingdry gas from the product fluid may be by channel guides 8 that act aswalls between adjacent plates. In the end of channel 4, a barrier orwall 12 prevents the working dry gas from exiting and mixing with theproduct fluid. If plate 6 is corrugated, the channel guides arepartially provided by the corrugations in the plate itself. The channelguides would be present on either or both sides of plate 6 and betweenthe product fluid and working gas to prevent passing of fluids betweenthe corrugations of the opposite plate. In either case, they function tochannel the gas or fluid streams, and may also advantageously maintainthe separation of plate 6 with other plates, in those embodiments havingmore than one heat transfer plate. In addition corrugated channel guidesmay be used in between flat plates 6, in which case no additionalseparation is needed.

Wet side 10 of plate 6 may advantageously include a wick layer materialcapable of transpiring the cooling liquid across wet side 10.Preferably, the wick layer may cover substantially the entire surfacearea of wet side 10. The wick layer may comprise any of a number of wellknown materials: cellulose, organic fibers, organic-based fibers, porousplastics, carbon-based fibers, polyesters, polypropylene, fiberglass,silicon-based fibers and combinations of these substances. The wicklayer material may be in a number of forms: films, weaves, braids, bedsof particles such as beads and combinations thereof.

Advantageously, the wick layer material may be the material of plate 6.For example, plate 6 may be a wick layer material treated on one side tomake it impermeable, the impermeable side then being used as the dryside of plate 6. The treatment may consist of changing the nature of thewick layer material itself, or coating it with another substance such asa plastic film or equivalent. The wick layer material may be treated tobe of low permeability instead of being entirely impermeable. In thisapplication, “low permeability” means that the amount of water allowedthrough plate 6 to dry side 9 is small enough that the gas streamscrossing dry side 9 do not become substantially humidified and are notsubstantially cooled by evaporation. Substitution of a low permeabilitydry side for an impermeable dry side nonetheless allows practice of theinvention as claimed herein.

Alternatively, the material of plate 6 may be impermeable and treated torender it permeable or to wick on the wet side 10. In either case, thematerial of plate 6 should have a relatively high resistance to heattransfer. While this has almost no effect on heat transfer through plate6, because it is thin, heat cannot be transferred laterally across theplate, as discussed earlier.

Plate 6 may also receive its cooling liquid from a feeder wick, as willbe discussed below in reference to other embodiments.

Perforations 11 may advantageously be round or other shapes having nocorners, or shapes such as polygons with rounded corners not only toincrease the durability of the plates but also in order to help preventturbulence in gas stream 2 as it is passing there through. By preventingturbulence, the pressure drop across the indirect evaporative cooler maybe minimized, with corresponding increases in efficiency of operationand reduction in construction costs. The perforations may be passages,such as micro pores, rather than perforation.

Plate 6 may advantageously slope so as to prevent accumulation of excesswater, and/or to allow a lower edge of plate 6 to sit in contact with asupply of the cooling liquid, such as a water reservoir, whereby thewicking material may act to keep wet side 10 supplied with coolingliquid. By keeping the slope quite low, from approximately −10 degreesto approximately +10 degrees, the transpiration of liquid across wetside 10 is rendered much more efficient. At greater angles of slope, themaximum wicking height of the wicking material unduly limits the widthof the plates. In extreme cases, transpiration may be renderedinefficient or impossible, thus reducing the amount of evaporativecooling achieved due to an inadequate supply of cooling liquid toevaporate. Depending on the nature of the wick layer material, the wickmay not transport liquid to the entire wet side 10, leaving some areasdry, or it may leave some sections surface dry but without enough liquidfor efficient evaporation to create high levels of relative humidity inthe working gas stream. Thus a low angle provides considerably moreefficient wicking, and for a given maximum wicking height, allowsgreater width.

Plate 6 may also have a double-sloped “V” cross-section as isillustrated in FIG. 7 and FIG. 8, that is, plate 6 may in cross-sectionresemble a shallow valley with a median section lower than two opposingedges or wings. The two slopes may be of different lengths or angles ofslope, or may differ in nature of wick layer material or other factors.

Plate 6 may also be equipped with a “stream selection damper” (notshown), allowing selection of only the coldest gas streams from the dryside of plate 6 (i.e. those also it may include damper to select somehumid working gas to add humidity to the environment to the center ofthe plates), or all of the gas streams, or some intermediate selection.By allowing only the coldest streams to be used for cooling, a smallerbut colder gas flow is provided; use of a larger selection of the gasstreams provides a larger gas flow. Also the damper may select humidworking gas for use in humidifying an environment.

FIG. 1d is a three dimensional perspective and schematic representationof a second embodiment of the element of the invention. In thisembodiment, plate 6 has perforations 11 along one side rather than downthe middle, as in the previous embodiment. Channel guides 8 createchannels 3 and 4. In this embodiment, channel guides 8 are ribs, butthey may be other types of guides, as previously discussed. Channelguide 8 also serves to prevent flow of gases off of one edge of plate 6.Working gas stream 2 flows in channel 4, product stream 1 flows inchannel 3. Gas stream 2, the working gas, flows through perforations 11to channel 5 (not visible), and then flows across the obverse side ofplate 6 to depart plate 6 as gas stream 2.

FIG. 2 is a three dimensional perspective and schematic representationof a third embodiment of the invention, showing the gas flow path whenthe invention is used to warm and humidify an air stream with water.Thus, in this embodiment and those following, the gas steams may bereferred to as air streams, and the cooling liquid will be assumed to bewater. In winter months, it is advantageous to exchange heat betweenexhaust air leaving a warmed space and cold fresh air being brought infrom the atmosphere, i.e. the out door air or other source ofenvironmental air. This reduces the heat required to warm the fresh air.The present invention also allows the addition of humidity to the freshair, thus addressing another winter problem: cold outside air that hascondensed moisture out and therefore has a low absolute humidity orextremely dry air that results in dry inside air as the moisture on theinside reduces with fresh air changes with the outside. The “cycleselection” as to which stream of air is exhausted to the atmosphere, andwhich goes to the space to be conditioned, is a feature of embodimentshaving this arrangement.

In FIG. 2, Plate 6 has dry side 9, wet side 10, channel guides 8, andperforations 11. Air steam 1 exits the conditioned space as air streams.Meanwhile, fresh air 2 enters and flows through perforation 11. As inthe two previous embodiments have shown, plate 6 acts as a heatexchanger to remove heat by conduction from air stream 1, on dry side 9.On wet side 10, air stream 2 flows through channels on the wet side (notvisible) and other parallel channels, receiving both heat (viaconduction and radiation) and humidity (via evaporation) from wet side10. Wet side 10 may have a wick material, as discussed previously, andthe construction of plate 6 regarding permeability, materials,treatments, feeder wicks, channel guides, corrugations, perforations,stream selection dampers, etc, may also be as previously discussed. Inthis manner, energy already used to heat air stream is conserved whilehumidity is added to the fresh air stream 2.

A “cycle selection damper” (not shown) provides the ability to switchbetween the cooling cycle and the warming/humidification cycle. At thesimplest, the cycle selection damper may simply be used to select whichstream of air is passed to the space to be conditioned: the air whichpasses only across the dry side 9 or the air which passes across bothdry side 9 and wet side 10. The damper may also provide differentsources for the air streams 1 and 2, as will be obvious to those skilledin the art.

FIG. 3 is a partially three dimensional perspective and schematicrepresentation of the flow path of an embodiment of the invention in anassembly showing the gas flow when the invention is used for cooling,and further showing the gas stream in the context of use. In thisembodiment, one gas stream is air from a conditioned space. Since thatair frequently emerges from the conditioned space cooler and dryer thanoutside air or cooler than desiccated air, it can profitably be used asthe working stream in the evaporative cooler of the invention.

Indirect evaporative cooler plate 6 comprises channel guides, aplurality of perforations (collectively numbered 11 for convenience).Dry product air stream 1 is provided by a desiccation wheel 25 andenters channels 3 on the dry side. Flowing across plate 6 on the dryside, it transfers heat to plate 6, emerging cooler but without addedhumidity. Air emerges from conditioned space 24 as working air stream 2,which flows into indirect evaporative cooler plate 6 in channel 4, whereit again transfers some heat to plate 6 by conduction before it passesthrough perforations 11 into the channel on the wet side. On the wetside of plate 6, air stream 2 is cooled by evaporation andsimultaneously cools plate 6 by the same action, before being expelledas air streams 2.

Desiccant wheel 25 may contain a liquid or solid desiccant of knowntype. The desiccant within desiccant wheel 25 must be recharged, thatis, must have the water it has absorbed from air stream 1 removed. Thisis accomplished by reactivation air 27, which flows through air heater26 before entering desiccant wheel 25. The high temperature ofreactivation air 27 removes from the desiccant humidity absorbed fromair stream 1. An additional heat exchanger may be used to transfer heatfrom air stream 1, after it has been heated and dried by flowing throughdesiccant wheel 25, to reactivation air 27, before air heater 26 heatsit, this technique is known in the art. However, it will be appreciatedthat neither the present embodiment nor the presently preferredembodiments described below use such an additional heat exchanger, asthe present invention provides highly efficient cooling to near dewpoint temperatures, while the additional heat exchanger adds over 45percent to the cost of the overall system.

FIG. 4 is a partially three dimensional perspective and schematicrepresentation of the flow path of a fifth embodiment of the inventionshowing the gas flow when the invention is used with recirculating gassteams, and further showing the gas flow in the context of use. In thisembodiment of the invention, air from a conditioned space is cooledagain and returned as the product fluid. This results in a saving ofenergy and additional cooling of the product air stream.

Plate 6 has channel guides, channels, and a plurality of perforationscollectively numbered 11. Air stream 1 emerges from desiccant wheel 25before passing over the dry side of plate 6 in channels, where ittransfers heat to plate 6 by conduction. Air stream 1 is then passed toconditioned space 24 and eventually recirculated to desiccant wheel 25.

Channel guides segregate working air stream 2 from product air stream 1after desiccant wheel 25. It passes through channel, where it rejectsheat to plate 6 and flows through perforations 11 to the wet side of theplate. As in previous embodiments, wet channel is not visible, butarrows indicating working air streams show that there may be a pluralityof wet side channels. At this time, working air streams 2 absorb heatfrom plate 6 by evaporation, radiation and conduction, cooling plate 6.

FIGS. 5 and 6 are three dimensional perspective and schematicrepresentations of a large plate containing the elements of theinvention, showing dry side gas flow, wet side gas flow, throughchannels not shown but present on the obverse side, additionalperforations, and additional channel guides, while FIG. 7 is across-sectional view of FIG. 5, showing gas flow on the wet side.

Evaporative cooler has product gas streams, working gas streams, productchannels, working channels, wet side channels, wick material, channelguides, dry side, wet side, perforations, block, and feeder wick holes.

In use, working gas or product fluid streams respectively flow intochannels 4 and 3, transferring heat to the heat exchanger withoutincrease in humidity. Working gas stream flows through perforations intowet side channels 5. FIGS. 7 and 8 show that evaporative coolercomprises a plurality of plates (the three diagrams respectively showone FIG. 5, two and three plates FIG. 7, but the number of plates is notlimited to this range FIG. 16). The plates may be “identical” in thesense of having channels on both sides cooperating with perforations 11to allow gas streams to flow through the plates, being composed ofmaterials having a poor lateral heat transfer rate and being impermeableon one side, with dry sides opposing each other across the plate spacingand wet sides opposing. The plates of the invention may also bedimensioned and configured to embody the invention without beingidentical. The plates are aligned in parallel and have like sidesfacing. In this application, “like sides facing” refers to the fact thatwet sides face the wet sides of other plates while dry sides face otherplates. It does not refer to the placement of perforations 11, whichwill be discussed further below.

In wet side channels, air stream receives heat from the plates ofevaporative cooler 6 by the mechanisms previously described. Also asnoted earlier, working gas stream 2 is itself pre-cooled by its passageacross the dry side of the plates of the evaporative cooler 6 in channel4, resulting in further cooling action by the device of the invention.Further as noted earlier, the gas streams may be selected based uponheat rejection (coolness) for service either as product or working airor with or without humidity. Thus, block 12 seals the end of channels 4,requiring all of air stream 2 to flow through perforations 11 to the wetside channels. Under different conditions, some of air stream 2 may beallowed to leave the end of channel 4 by removal of block 12, resultingin a greater volume of slightly less cool product air, or in thealternative, some of air stream 1 may be diverted or blocked (thatportion of air stream 1 which was furthest from the center ofevaporative cooler 6 and thus received the least cooling), thusproducing a smaller quantity of slightly cooler product air. Otheralternatives for the construction of the invention are also as describedearlier.

Thus, air streams in this assembly flow between two plates rather thanacross one plate. If two such plates are aligned with dry sides facing,then the air streams flow between the two plates on the dry sides, ifthe wet sides are facing, the air streams flow between the plates on thewet sides. In embodiments having more than two plates, air streams willfirst flow between the dry sides of two plates, then will flow throughone or both plates and enter wet channels, in which they will flowacross one of the two previous plates (on the reverse side) and the wetside of a third plate.

In one embodiment feeder wicks may pass through feeder wick holes 23 inorder to supply water to wick material 7, and will be discussed withreference to FIGS. 8 and 9.

FIG. 9 is a partially exploded perspective views of another embodimentof the invention, including schematic representations of gas flow, asviewed from two different angles.

Indirect evaporative cooler 14 is built up in approximately a box shape,although this shape may be optimized to suit conditions, as is wellknown in the art. A plurality of plates 6 forms the stack. Each ofplates 6 has a wet side 10 and a dry side 9, although for the sake ofclarity these are referenced for only the topmost plate 6. Plates 6 arealigned in parallel and oriented with like sides facing, so wet sides 10face wet sides 10 and dry sides 9 face other dry sides 9.

It is advantageous to provide plates 6 in which perforations 11 do notline up directly facing the perforations in adjacent plates. Instead, inthe preferred embodiments of the invention, perforations 11 are offsetfrom the perforations 11 in the next plate 6. This helps to reduce thepressure drop across the evaporative cooler 14, thus reducing the energyrequired by the device and increasing efficiency. In addition thiscreates better distribution of air in the evaporative channel 5.

Cooler 14 also has water reservoir 17, pump 15, and feeder wicks 13.Water 7 is removed from water reservoir 17 by pump 15 and lifted tofeeder wicks 13. A reservoir refill line 8 allows water reservoir 17 tobe continuously refilled or refilled as desired.

Although spacing of the plates may be any amount for some gases orfluids, spacing of plates 6 is important to efficient use of theinvention. If the spacing is properly selected, pressure drop of the gasstreams passing through the invention is greatly reduced, providingeither greater flow or the ability to use smaller or fewer fans orblowers. Experiment has shown that an inter-planer spacing of 1.5 to 3.5millimeters is preferable, and spacing within the sub-ranges of 1.50 to1.85 millimeters, 2.00 to 2.35 millimeters, 2.10 and 2.90 millimetersand 3.10 and 3.50 millimeters is more preferable. Without being bound byany particular theories, it is believed that at these spacings, standingwaves are set up which reduce drag during the flow processes. It is alsopossible that at these spacings, turbulent, non-laminar flow isdiscouraged, which may also serve to reduce drag and pressure drop inthis particular process. The proper spacing may be maintained byseparate structural elements (not shown) or may advantageously beprovided by the channel guides 8, which may be provided ribs orcorrugations of plate 6, or by other means.

Feeder wicks 13 comprise tubes having a wick material covering at leasta portion of the outside of the tube. Holes through the tube allow water7 within the tube to reach and wet the exterior wick material, which isin contact with the wick material on wet sides 10. Water 7 flows outthrough the holes into the exterior wick material. From there it, maytranspire from the wick material of the feeder wick to the wick material7 of wet sides 10 and so across such portion of wet side 10 as iscovered by wick material 7.

Product fluid stream 1 enters channels 3, while working air stream 2enters channels 4, both on the dry sides 10 of plates 6. Working airstream passes through perforations 11 into wet side channels 5,functioning as previously described cooling plates 6. Note that for thesake of clarity, only four working air streams are shown exiting thecooler 14 and only one entering it, but there may be any number, andthey may (and in this preferred embodiment do) exit from both sides ofcooler 14.

Channel guides serve several functions. In addition to separating airstreams 1 and 2, they act to subdivide air streams 1 and 2 further, thuscreating better temperature distribution in the invention, creatingchannels having cooler product air 1 near the center of plates 6, helpto insure standing wave flow or laminar flow, thus reducing the pressuredrop across the device, and help to insulate the parallel subdivisionsof air streams 1 and 2, thus preventing parallel heat transfer. Finally,channel guides 8 also serve as structural members to support the stackand separate plates 6 by the desired distance.

Block 12 (visible in FIGS. 8 and 9) prevents working air 2 from leavingthe device via channels 4, thus forcing it to flow through wet channels5. Stated differently, the outlet for wet channels 5 will always bedownstream of the perforations. As stated previously, in alternativeembodiments, some product air may also be blocked/diverted or someworking air allowed to leave as product air in accordance withrequirements and conditions.

As previously discussed, the amount of pre-cooling which air stream 2undergoes, is in part determined by selection of perforations andchannel sizing. Also as discussed previously, the material of plate 6provides poor lateral heat transfer, thus in turn providing atemperature differential or gradient laterally across plate 6. Channelselection dampers (not shown) may advantageously be used to select whichof the subdivisions of air streams 1 and/or 2 are used for conditioning,thus allowing a greater degree of cooling than otherwise, as well asproviding for flexible control of the output gas temperature, humidityand quantity.

Fans or equivalent blower devices are schematically represented as 19and 20, but the invention is subject to alternative embodiments of thefan arrangement. For example, one fan as forced draft may be used toprovide both working and product air streams 1 and 2. In addition, aforced draft fan has advantages over an induced draft. Due to theevaporative process used by the device, the parasitic heat added by thefan motor to airstreams 1 and 2 is efficiently used to further evaporatewater 7 and thus the heat aids in its own removal, resulting in littledifference to the temperature of final product air stream 1. A forceddraft fan provides air to both the working air and product air channelsaccording to the pressure drop through each and any outside dampers thatmay be used. Finally, since the working and product air emerge atdifferent outlets, two fans are required to induce two drafts, whileonly one fan is required to force both drafts.

Stack 14 may be enclosed in a housing (not shown), which housing mayfurther direct and control airflow, as well as enhancing the estheticsof the device. The housing may comprise inlets and outlets for theproduct and working air streams, and a damper to allow the direction ofairflow to be controlled. For example, when the damper is in a firstposition, it may cause the cooler to operate normally, whereas when thedamper is in a second position, it may cause the warmed, humidifiedworking air to become the product air. This may be used in conjunctionwith recirculating air, as described above, to provide humidificationand pre-warming of winter air.

As in previous embodiments, the indirect evaporative cooler 14 may beused in conjunction with recirculating air streams, desiccant wheels,corrugated plates, and treatment of the material of the plates,perforations and other details.

Note that the indirect evaporative cooler of the invention may alsoaccomplish both direct and indirect evaporative cooling of the productair stream 1. A portion of the dry sides 9 may be wetted, in a mannersimilar to the wick materials used on wet sides 10 or in a differentmanner, so as to cause further cooling of the product air stream. Thiswet portion of the dry sides may advantageously be placed downstream ofthe dry portion of the dry sides, so that prior to being humidified inthe direct evaporation cooling process, the sensible temperature of theproduct air stream 1 is reduced as much as possible. One particularadvantage of this ordering is that below approximately 65 degrees F.,modest increases in humidity cause disproportionate reduction in airtemperatures, in accordance with standard psychometric charts. Inanother embodiment of the invention, this wetted portion of the drysides constitutes the final 1 to 25 percent of the surface area of thedry channels 3.

FIG. 10 is a three dimensional perspective and schematic representationof another embodiment of the invention, showing gas flow and a reservoirof water.

Evaporative cooler 6 has dry sides, wet sides 10, product air stream 1and working air stream 2, channel guides 8, channels 3 and 4 and wetchannels 5, as well as water reservoir 17. In this embodiment, there isno need for a water pump or feeder wicks because the wick material ofwet sides 10 is directly placed in water reservoir 17. However, thewidth of the plates of cooler 6 is limited to the maximum wicking heightof the wicking material unless the plates are sloped, as describedearlier, which slope also allows more efficient wicking. This embodimentis also an example of an indirect evaporative cooler of the invention,which uses exhaust from only one side of the plates.

In FIG. 8, the two wings of the cores extend out and upward from thecenter. In the center, as depicted is a feeder wick plate thatcommunicates liquid used for the evaporative cooling in the wet channelsto the wick material layers of the core.

In FIG. 8, the wings are angled upward, between approximately 0 degreesand +10 degrees. An alternate is illustrated in FIG. 11, where the wingsare angled downward from the center, also within the approximate rangeof slope of 0 degrees to −10 degrees.

The selection of upward or downward sloping wings will also include aselection of wick material in the wet surfaces of the layers, so thatthe liquid migrates over the entire surface of the wick material surfaceof each plate.

The advantage of the downward slope is that the liquid will more readilyreach the edges due to the added impetus of gravity. This will aid inthe reduction in the scale build up on the edges that can occur withliquids that have mineral content.

The added assistance of gravity (or downward sloping wings) is that itallows more length of the wings to be wetted from the center feeder wickand it will be accomplished faster.

The potential of excess water being collected at the outer edges of thewings in a downward sloping core, is that liquid droplets will form.Also when excess liquid is being cooled, unnecessary cooling of theliquid diminishes the efficiency of the evaporative cooler. To minimizethe excess water, the wicking material on the layers will be less porousthan the feeder wick.

The upward angled wings, FIG. 8, will not have the excess watercollecting at the edges of the layers. The more likely issue is notenough water reached the outer edges, resulting in lost coolingpotential and the build up of minerals at the dry edges.

The embodiments of the feeder wick plates 13, shown in FIGS. 12, 13, and14, are refinements of a solid feeder wick plate. The purpose of thechannels or grooves 50, FIG. 12, the holes 51, FIG. 13, or the sandwich,FIG. 14, all are to enable quicker movement of liquid from the top,where liquid is introduced to the feeder wick plate, to the bottom andthus more quickly wet the core wick material. Alternate methods toaccomplish the distribution aid may include rods 57 placed along thesides of the feeder wick.

The channels, holes and more porous core of these embodiments will allowliquid to move throughout the feeder wick plate and, thus, aiddistribution of the evaporative liquid.

The channels, holes or cores may not extend all of the way to the bottomof the feeder wick plate, as this would allow the liquid to too easilypass through these passageways before wetting the feeder wick.

FIG. 15 illustrates a set of core sections with a gap 55 betweenadjacent sections. This gap performs a function of breaking up thecanalized air streams into discrete segments. This in turn reduces thebuild up of boundary layers in the channels, which prevents efficientheat transfer. Where the channels are small or the velocity is low, thefluid tends to be in laminar flow. In the boundary layer next to theplate in the dry channels the heat transfer rate is lower. This boundarylayer is nil at the entrance of the plate and grows to some steady stateamount with in the first few inches. Therefore the heat transfer rate issignificantly greater at the entrance to any channel and reducesexponentially to some smaller steady state amount.

An embodiment of the reservoir system is shown in FIG. 16 and in FIG. 17in conjunction with the cores and feeder wick plates.

The top reservoir 60 feeds liquid to the feeder wick plate. The topreservoir is fed by a valve and piping with the appropriate liquid. Asthe reservoir feeds the feeder wick, excess liquid passes to the lowerreservoir 61.

A float valve 62 relies upon the level in the lower reservoir toactivate the supply valve 63 for the upper reservoir.

As the wick takes liquid to the wick material on the layers of the core,the upper reservoir 60 is depleted. If there is more evaporate thanexcess liquid draining into the lower reservoir 61, the float 62 will belower. As it gets lower it activates the supply valve 63 to add moreliquid to the upper reservoir 60.

As there becomes an excess of liquid fed to the feeder wick plate 13,more than can evaporate, the excess collects in the bottom reservoir 61,which raised the float and in turn cuts off the supply valve to theupper reservoir. This system does require a continual bleeding off ofwater from the bottom reservoir such that it can sense the waterentering the system. This bleed drain also helps to prevent mineralconcentration.

In this way the evaporation rate determines the need to add or diminishthe liquid to the feeder wick core.

Added features would include an over flow drain 64, cold turn off anddrain system 65. A Thermostat may activate the supply of liquid to thereservoir in any commonly arranged systems.

FIG. 18 illustrates another embodiment of the heat exchanger plate, aType 1 plate 70, with a trough 72 on the bottom and a Type 2 plate 71.The Type 1 and 2 plates perforations 11 for gas flow 2 are outside theformed trough. The trough 72 is used to hold and to distribute theliquid 1 used on the wet sides of the plate. In the Type 1 plate the wetside 10 is viewable. With the wick acting material 7 on this surface andthe surface of the trough that is viewable.

The liquid perforations 73 in the trough area are for the liquid to passthrough to the next layer. With the wet side wick material 7 is on theupper side, the liquid perforations 73 are on the sides of the trough72. This allows a reservoir 74 of liquid to be kept at this layer, toallow the liquid to be wicked outward to the sides of the plate. By theliquid perforations 73 being on the sides, the reservoir 74 will be upto this level. For the next layer up (or Type 2 plates 71) with its wicklayer on the underside, the similar trough 72 form will be partiallysubmerged in the reservoir 74 liquid and thus, the wick material 7 onthis layer will be fed the wetting liquid from this reservoir 74. Bothopposing wet surfaces will get the liquid from this one reservoir.

On the wet side the working gas channels 4 angle toward the outer edgesas in the other embodiments and receive working gas 2 from the dry side9 through the gas perforations 11 as in the other embodiment. The flowof the working gas 2 helps to distribute the liquid outward on the wetside of the plate.

In Type 2 plates 71, the product channels 3 and the working channel 4are segregated by channel guides 8. The liquid perforations 73 arelocated in the bottom of the trough to allow the liquid that comes fromthe plate reservoir above or from a feeder tube 75 to drain down to thereservoir below in the next lower plate.

When there are multiple plates, with wet sides opposed to form workingor wet channels 4 and the obverse sides forming dry channels 3 thetrough 72 forms are nested. The liquid 1, wherever it enters the stackwill cascade downward collecting in each Type 1 trough, the liquid inthe wet channel reservoir 74. This flow is illustrated in FIG. 19.

FIG. 20 shows a more complete stack 14 with a feeder tube 75 todistribute liquid 1 to the top trough. On the ends, as in FIG. 8, is abarrier 12 to seal the working gas passage 4 so as to direct the workinggas 2 through the gas perforation 11 into the adjoining wet workingchannels 4. The product channels 3, as in FIG. 18 are segregated fromthe working gas channels 4 for the dry side of the plates.

FIG. 21 is, similar to FIG. 20 and illustrates a stack 14 using thetrough 72 with two feeder tubes 75, one at the top and one at a middlelevel. This allows for priming of the liquid reservoirs 74 for a quickstartup. This may be accomplished in other ways known in the art,including multiple entry points. The sensors 76 illustrate how theliquid level is detected in the bottom reservoir 61. If it is too dry,the controller opens the supply valve 63 to supply more liquid to theliquid feeder tubes 75. Conversely, if the bottom reservoir 61 is toowet, the flow to the feeder tubes is cut back. The usage of the liquidby the wet channels in evaporation diminishes the flow of liquid whichminimizes the liquid that gets to the bottom reservoir 61. When thissituation occurs the sensor 76 detects the low level and signals formore liquid. Sensors 76 could be placed in wet channels or at places inthe stack 14 or in trough reservoirs 74 as understood by thoseknowledgeable in the art.

The use of plastic, cellulose or other pliable materials may not besuitable for the heat transfer membranes in some applications whererefrigerates or steam are condensed with pressures and indirect cooling.The channels for the product fluid may need to be a metal such asaluminum or other suitable stiff and walled structures, such as tubeswith the walls being the heat exchange surface.

By pre-condensing and cooling refrigerates, with indirect cooling incores such as the disclosed invention, efficiencies of less pressure areneeded to compress the gaseous refrigerant during its cycles can saveheat build up and power usage.

The use of cores as disclosed is more efficient and less costly thancooling tower and as such, capable of by incorporation into residentialsystems.

The invention and the embodiments described herein are susceptible tomany equivalents, alterations and additions without departing from thescope of the invention. This description in no way limits that scope,which is determined by the following claims.

We claim:
 1. A plate for heat exchange and indirect evaporative coolingof at least one fluid stream, the plate comprising: a) a dry side havinglow permeability to an evaporative liquid; b) a wet side with itssurface wet by an evaporative liquid; c) the dry side of the plateseparated by first channels into two sections, a working stream sectionand a product stream section with at least one passageway through theplate in the working stream section to allow the working gas on the dryside to transfer to the wet side of the plate; d) a trough shape formedin a portion of the plate; and e) the trough portion having liquidperforations.
 2. The plate of claim 1, further comprising secondchannels on the wet side of the plate oriented in a direction other thanparallel to the fluid flow on the dry side.
 3. The plate of claim 2,wherein one or more first channels are oriented at an angle to the oneor more second channels, whereby the direction of flow of fluids acrossthe dry side of the plate is substantially perpendicular to thedirection of flow of gases across the wet side of the plate.
 4. Theplate of claim 3, wherein the plate comprises a material having a lowrate of heat transfer, but with a thin cross-section that allows heat tobe readily transferred from the dry side to the wet side, even with thelow rate of heat transfer of the material.
 5. The plate of claim 1,wherein the channel aids laminar flow across at least one side of theplate.
 6. The plate of claim 1, wherein the plate further comprises aplurality of ribs extending parallel to the direction of gas flow acrossthe plate, and further wherein the ribs provide the channels.
 7. Theplate of claim 1, wherein the channels are provided by corrugations ofthe plate.
 8. The plate of claim 1, wherein the perforation is one ofthe shapes belonging to the group consisting of: round and polygonalhaving rounded corners.
 9. The plate of claim 1, wherein at least aportion of the plate is oriented so as to slope at an angle of from −10to +10 degrees from the horizontal.
 10. The plate of claim 9, furthercomprising a reservoir of water, wherein the lowest edge of the plate isin contact with the water.
 11. The plate of claim 1 wherein the top sidehas the a wick material and the liquid perforations are on the sides ofthe trough near the top.
 12. The plate of claim 11 wherein the wickmaterial is on the bottom side and the liquid perforations are near thebottom of the trough.
 13. An indirect evaporative cooler comprising: a)a plate having dry and wet sides, the wet side being at least partiallywet by an evaporative liquid, and further having two or more firstchannels across the dry side of the plate and one or more secondchannels across the wet side of the plate; and b) a product flow streamand a working gas stream separately flowing across the dry side andthereby transferring heat to the plate; c) a passageway through theplate in the area of the working stream on the dry side, the workingstream flowing through the perforation from the dry side to the wet sideand further flowing across the wet side; d) the plate transfers heat tothe working gas stream on the wet side by direct evaporative cooling andthereby cooling the plate and the product flow and working gas streamsflowing on the dry side; and e) a trough formed in a portion of theplate to hold and transfer the evaporative liquid to the wet side of theplate.
 14. The indirect evaporative cooler of claim 13, furthercomprising: a) a second plate having first and second sides, the firstof a dry side and the second side of the second plate being partiallywet by an evaporative liquid, and further having two or more firstchannels across the dry side of the second plate and one or more secondchannels across the wet side of the second plate, and having apassageway through the second plate in the area of the working gasstream on the dry side; b) aligned in parallel with the first plate,spaced apart therefrom, and oriented so as to have wet sides of thefirst and second plates opposing, and further wherein the working gasstream from the dry side of both the first and second plate flow throughto the space separating the plates on the wet sides and the troughportions are oriented and nested with each other; and c) the productfluid passes across and is cooled on the dry sides of both the first andsecond plates.
 15. The indirect evaporative cooler of claim 14, whereinthe spacing between the plates is chosen to minimize the pressure dropof the gases flowing between the plates.
 16. The indirect evaporativecooler of claim 15, wherein the spacing between the plates is furtherchosen to be between 1.5 and 3.5 millimeters.
 17. The indirectevaporative cooler of claim 16, wherein the spacing between the platesis further chosen to be in one of the ranges in the group consisting of:1.50 to 1.85 millimeters, 2.00 to 2.35 millimeters, 2.10 and 2.90millimeters and 3.10 and 3.50 millimeters.
 18. The indirect evaporativecooler of claim 14, wherein at least one passageway through each plateis offset from the passageways through the other plate.
 19. The indirectevaporative cooler of claim 14, wherein one or more channels on the dryside are oriented at an angle to one or more channels on the wet side,whereby the direction of flow of fluids across the dry sides of theplates is substantially perpendicular to the direction of flow of gasesacross the wet side of the plates.
 20. The indirect evaporative coolerof claim 14, wherein the product stream and the working stream aredehumidified prior to flowing across the dry sides of the plates. 21.The indirect evaporative cooler of claim 14, wherein at least one of thestreams, the product stream or the working stream are passed through adesiccant dehumidifier prior to flowing across the plates.
 22. Theindirect evaporative cooler of claim 14, wherein the product stream isrecirculated from the space to be cooled to be reused as the workingstream and/or the product stream.
 23. The indirect evaporative cooler ofclaim 14, further comprising: a) a barrier dimensioned and configured toprevent the working stream from exiting the indirect evaporative coolerprior to passing through the perforations.
 24. The indirect evaporativecooler of claim 14, wherein the channels comprise a plurality of ribsextending parallel to the direction of fluid flow across the sides ofthe plates and the opposing surfaces of adjoining plates.
 25. Theindirect evaporative cooler of claim 14, wherein the channels areprovided by corrugations of the plates.
 26. The indirect evaporativecooler of claim 14, usable in either cooling a space or assisting inwarming and humidifying the space, further comprising: a) a cyclecontrol damper having first and second positions such that when thecycle control damper is in the first position, the working gas stream isexpelled into the atmosphere and the product stream is directed tocooling the space, and when the cycle control damper is in the secondposition, the product stream is expelled into the atmosphere and theworking stream is directed to warm and humidify the space.
 27. Theindirect evaporative cooler of claim 14, further having at least one fanarranged so as to aid the motion of the product fluid and working gasstreams.
 28. A method of indirect evaporative cooling comprised of thefollowing steps: a) having a heat transfer surface; b) wetting oneportion of the heat transfer surface with an evaporative liquid that isheld temporarily in a trough formed in the heat transfer surface; c)having gas pass through the heat transfer surface from the dry portionto the wet portion; d) passing a product fluid stream across the dryportion of the heat transfer surface to be cooled and used; e) passing aworking stream across the dry portion of the heat transfer surface wherethere are passages; f) the working stream flowing through the passagesin the heat transfer surface to the wet portion of the heat transfersurface; g) cooling of the heat transfer surface by evaporation of theevaporative liquid into the working stream on the wet portion of theheat transfer surface; and h) cooling the product stream and workingstream by contact with the cooled heat transfer surface in the dryportion.
 29. The method of claim 28 where the guides on the dry side runparallel to the side of the plate with the passages.
 30. The method ofclaim 28 where the guides on the wet side run at a direction other thanparallel to the guides on the dry side.
 31. An improved method to cool afluid where it is comprised of the following steps: a) having a platefor the heat transfer surface; b) using two or more plates; c) havingadjacent plates with their opposed surfaces being of the same type, suchas both wet surfaces, thereby forming a spacing between the adjacentplates; d) having guides between adjacent plates to guide the fluid ofthe product stream and working stream in desired directions; e) havingthe passages in all of the plates being in the same area; f) having theguides in the dry space between adjacent plates guide the product streamseparate from the working stream; g) having the guides in the wet spacebetween adjacent plates guide the working stream after it has enteredthe wet space in a direction other than parallel to the direction of theproduct stream yielding cool fluid of the product stream without anyaddition of humidity; and h) having the trough areas nested with eachother and holding the evaporative liquid temporarily to wet the wetsides of the plates.
 32. The method of claim 31 where the liquid for thewet surfaces is distributed by a wicking layer on the wet side of theplates.
 33. The method of claim 31 where the plate has a layer on thedry side that is impermeable to the evaporative liquid.
 34. The methodof claim 31 where the wick layer of the plates is furnished evaporativeliquid by liquid in the trough reservoirs.
 35. The method of claim 31where the trough reservoirs are furnished evaporative liquid and theliquid that is not taken by the wick material exits the trough throughliquid perforations.
 36. The method of claim 35 where the reservoir wetsthe wick material on two adjacent plates.
 37. The method of claim 35where there is a bottom reservoir.
 38. The method of claim 35 wherethere is a means to sense whether more liquid is needed for the wickmaterial.
 39. The method of claim 38 where the means is a float valve ina reservoir.